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EP2742055B1 - Verfahren zur herstellung von polymeren mit erhöhter glasübergangstemperatur aus biobasierten erneuerbaren (meth)acrylierten monomeren in anwesenheit von vinylestermonomeren oder ungesättigten polyestermonomeren - Google Patents

Verfahren zur herstellung von polymeren mit erhöhter glasübergangstemperatur aus biobasierten erneuerbaren (meth)acrylierten monomeren in anwesenheit von vinylestermonomeren oder ungesättigten polyestermonomeren Download PDF

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Publication number
EP2742055B1
EP2742055B1 EP12845143.2A EP12845143A EP2742055B1 EP 2742055 B1 EP2742055 B1 EP 2742055B1 EP 12845143 A EP12845143 A EP 12845143A EP 2742055 B1 EP2742055 B1 EP 2742055B1
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Prior art keywords
monomer
weight
vinyl ester
anhydrosugar
unsaturated polyester
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French (fr)
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EP2742055A4 (de
EP2742055A2 (de
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Giuseppe R. Palmese
John Joseph La Scala
Joshua Matthew SADLER
Anh-Phuong Thy LAM
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Drexel University
US Government
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Drexel University
US Department of Army
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F120/00—Homopolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride, ester, amide, imide or nitrile thereof
    • C08F120/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F120/10—Esters
    • C08F120/26—Esters containing oxygen in addition to the carboxy oxygen
    • C08F120/28—Esters containing oxygen in addition to the carboxy oxygen containing no aromatic rings in the alcohol moiety
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07D—HETEROCYCLIC COMPOUNDS
    • C07D493/00—Heterocyclic compounds containing oxygen atoms as the only ring hetero atoms in the condensed system
    • C07D493/02—Heterocyclic compounds containing oxygen atoms as the only ring hetero atoms in the condensed system in which the condensed system contains two hetero rings
    • C07D493/04—Ortho-condensed systems
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F122/00—Homopolymers of compounds having one or more unsaturated aliphatic radicals each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical and containing at least one other carboxyl radical in the molecule; Salts, anhydrides, esters, amides, imides or nitriles thereof
    • C08F122/10—Esters
    • C08F122/12—Esters of phenols or saturated alcohols
    • C08F122/20—Esters containing oxygen in addition to the carboxy oxygen
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F124/00—Homopolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a heterocyclic ring containing oxygen
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/10—Esters
    • C08F220/26—Esters containing oxygen in addition to the carboxy oxygen
    • C08F220/28—Esters containing oxygen in addition to the carboxy oxygen containing no aromatic rings in the alcohol moiety
    • C08F220/281—Esters containing oxygen in addition to the carboxy oxygen containing no aromatic rings in the alcohol moiety and containing only one oxygen, e.g. furfuryl (meth)acrylate or 2-methoxyethyl (meth)acrylate
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/10—Esters
    • C08F220/26—Esters containing oxygen in addition to the carboxy oxygen
    • C08F220/32—Esters containing oxygen in addition to the carboxy oxygen containing epoxy radicals
    • C08F220/325—Esters containing oxygen in addition to the carboxy oxygen containing epoxy radicals containing glycidyl radical, e.g. glycidyl (meth)acrylate
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F224/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a heterocyclic ring containing oxygen
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/10—Esters
    • C08F220/26—Esters containing oxygen in addition to the carboxy oxygen
    • C08F220/28—Esters containing oxygen in addition to the carboxy oxygen containing no aromatic rings in the alcohol moiety
    • C08F220/282—Esters containing oxygen in addition to the carboxy oxygen containing no aromatic rings in the alcohol moiety and containing two or more oxygen atoms

Definitions

  • the present invention relates to renewable vinyl ester resin systems made from bio-based monomers derived from non-petroleum celluloses or carbohydrates with a core scaffold of isosorbide, isomannide or isoidide.
  • Vinyl ester resins are thermosetting polymers that are commonly used in variety of applications ranging from adhesives to the resin matrices for fiber reinforced composites. There are many desirable features for vinyl ester resins, such as strength, toughness, low cost, low weight, and particular viscosities for processing, which are the reasons that vinyl ester resins have such wide acceptance in military and commercial uses.
  • Viscosity is a key factor for determining the utility of vinyl ester resins because lower viscosity resins are easier to work with and may be prepared using a larger range of methods.
  • Petroleum-based vinyl ester resins are typically high molecular weight species that are often an extremely viscous fluids or solids. They require reactive diluents in order to reduce the resin viscosity so that the resins can be processed.
  • Typical reactive diluents, such as styrene are generally regarded as Hazardous Air Pollutants (HAPs) and/or Volatile Organic Compounds (VOCs) whose use is controlled by the Environmental Protection Agency (EPA). Large research efforts have been devoted to finding ways to eliminate or reduce the use of these highly hazardous reactive diluents.
  • HAPs Hazardous Air Pollutants
  • VOCs Volatile Organic Compounds
  • Bio-refining of material based on converting biomass into vinyl ester products has been successfully developed.
  • bio-refining of triglycerides and carbohydrates have produced a wealth of new fine chemicals that are useful for the development of bio-based polymers.
  • Fatty acids and triglycerides have also been successfully developed into materials ranging from toughening agents and plasticizers to reactive diluent replacements.
  • U.S. Patent no. 6,121,398 discloses functionalized triglycerides derived from plant oil that are polymerizable and their use to produce high modulus polymers.
  • the functionalized triglycerides may be produced via several different chemical synthesis routes.
  • epoxidized triglyerides may be produced and converted to resilient rubbers by control of the molecular weight and cross-link density.
  • the resultant rubbers can be used as rubber toughening agents in rigid composites.
  • acrylated base resins are prepared by reacting the epoxidized triglycerides with acrylic materials such as acrylic acid.
  • thermosetting resins prepared by this method are said to have properties similar to commercially available bisphenol-A vinyl ester resins.
  • Other functionalized triglycerides are described in U.S. Patent 6,825,242 and U.S. patent application publication nos. US 2003/0139489 and US 2009/0275715 .
  • anhydrosugars derived from cellulose or carbohydrates such as isosorbide, isomannide and isoidide
  • these anhydrosugars are useful building blocks because they provide a rigid bicyclic core structure that can be developed into resins.
  • anhydrosugar, or bis-anhydrohexitols have been fashioned into epoxy resins by forming the corresponding glycidyl ethers, as described in U.S. Patent no. 3,041,300 (Zech, et al. ) and U.S. Patent no. 3,272,845 (Morrison, et al. ).
  • WO 2011/048739 A1 discloses (meth)acrylate monomers which have cyclic structures of the formula: wherein each R 1 is a hydrogen atom or (meth)acryloyl, with at least one R 1 being (meth)acryloyl, A is a Cz_4 alkylene and n is a number from 0 to 30.
  • GB 586 141 A discloses a method wherein polyhydric alcohols or their anhydrides or hexose derivatives are treated in caustic soda solution with the acid chlorides of unsaturated acids or in pyridine solution with the anhydrides of the unsaturated acids to provide esters. The esters are then polymerized by heating for a few minutes to the melting point or any other suitable temperatures.
  • U.S. Patent no. 7,723,461 B1 discloses polymers including components produced from renewable resources and methods for making them.
  • the polymers are made by polymerizing reactive intermediates derived from lactide or sorbitol with each other or with other resins.
  • the intermediates can be used to prepare vinyl ester-styrene resins and thermoset networks formed therefrom.
  • anhydrosugars have not been successfully used to produce low viscosity thermosetting vinyl ester resins.
  • Reactive diluents such as styrene are still commonly used for reducing viscosity of these bio-based resins.
  • Commercial practice involves reducing the styrene content in the resin to about 33 wt% styrene, which makes the resin barely acceptable for composite manufacturing applications.
  • reducing the styrene content significantly reduces the toughness of these resins.
  • the invention is directed to a copolymer as claimed in claim 13.
  • the invention is directed to a method for making a polymer as claimed in claim 1 as well as to use of certain anhydrosugar based monomers to enhance the Tg of a polymer as claimed in claim 14.
  • the anhydrosugar-based monomers can be used as viscosity modulators and Tg enhancers in vinyl ester resins, thereby allowing a reduction in the reactive diluent concentration while maintaining suitable polymer toughness.
  • FIG. 1 shows the synthetic routes for anhydrosugar-based monomers, using isosorbide as illustrative examples. Either isomannide or isoidide may be used in place of isosorbide in these synthetic routes.
  • anhydrosugar-based monomers for vinyl ester resin systems are disclosed.
  • the monomers are derived from plant cellulose or carbohydrates, which are completely renewable sources. Eight of these monomers derived from isosorbide are shown in Figure 1 as Products 1-2 and Products 4-9. Other monomers are derived from isomannide or isoidide using the same synthetic routes. These monomers may be used as low viscosity cross-linkers for thermosetting vinyl ester resins, which can replace petroleum-based vinyl ester thermosetting resins for nearly all of their applications.
  • anhydrosugar-based monomers are their relatively low molecular weight due to their confined core structure resulting from the limited carbon chain length of these naturally occurring sugars.
  • the low molecular weights of these anhydrosugar-based monomers can be used to reduce the overall viscosity of vinyl ester resins containing them, which, in turn, can reduce the dependency on reactive diluents. This has the advantage of reducing the use of reactive diluents, yet still producing vinyl ester resins with acceptable toughness and processability.
  • Figure 1 shows some of the applicable synthetic routes, using isosorbide as illustrative example. Similar synthetic routes are available for the other two anhydrosugars: isomannide and isoidide.
  • the starting materials, isosorbide, isomannide, or isoidide are industrially refined from naturally occurring sugars by a two-step process: 1) reducing glucose, mannitose, or idose, respectively; and 2) subjecting the reduced glucose, mannitose or idose to an acid catalyzed dehydration to produce a fused bicyclic ring system.
  • the anhydrosugars have formulae:
  • One method involves acylation of the hydroxyl groups of anhydrosugars using either acryloyl chloride or acryl anhydride and a base catalyst in an aprotic solvent.
  • a second method involves esterification of anhydrosugars using acrylic acid, catalyzed using either acidic or basic conditions.
  • a third method involves transesterification of anhydrosugars using methyl acrylate, catalyzed by either an acid or base catalyst.
  • the reacting ester can be any combination of a parent acid that is an acrylate and a matching alcohol used to form the ester which is 1-8 carbon atoms in length.
  • the small molecule alcohol of 1-8 carbon atoms is selected since it has a relatively low boiling point and can easily evaporate as the reaction progresses.
  • Synthetic route 2 of Figure 1 is similar to synthetic route 1 in that the anhydrosugars are functionalized using a variety of different methods to produce a methacrylated derivative, Products 2 and 2a, which are capable of free radical polymerization.
  • Products 2 and 2a have the formulae: and
  • One method involves acylation of the hydroxyl groups of anhydrosugars using either methacryloyl chloride or methacryl anhydride, catalyzed by a base catalyst in an aprotic solvent.
  • a second method involves esterification of anhydrosugars using methacrylic acid, catalyzed by either acidic or basic conditions.
  • a third method involves transesterification of anhydrosugars using methyl methacrylate, catalyzed by either an acid or base catalyst.
  • the reacting ester can be any combination of a parent acid that is a methacrylate and a matching alcohol used to form the ester which is 1-8 carbon atoms in length.
  • the small molecule alcohol of 1-8 carbon atoms is selected since it has a relatively low boiling point and can easily evaporate as the reaction progresses.
  • Synthetic route 3 of Figure 1 produces an intermediate referred to as Product 3 or Known 1.
  • the formula of Product 3 is:
  • Known 1 is treated with acrylic acid in the presence of a chromium based catalyst, such as AMC-2TM (Aerojet chemicals, Collinso Cordova, CA).
  • AMC-2TM Arojet chemicals, Collinso Cordova, CA
  • the reaction is carried out at 90-105 °C, with 2.0-5.0 wt % catalyst based on the total weight of the reaction mixture.
  • the synthetic route 4 can be carried out using another suitable method. For example, reaction of Known 1 with acrylic acid in refluxing acetonitrile catalyzed with 12-25 mol % tetrabutylammonium bromide (TBAB), based on the number of moles of Known 1, will also result in Products 4 and 4a.
  • TBAB tetrabutylammonium bromide
  • Known 1 is treated with methacrylic acid in the presence of a chromium based catalyst, such as AMC-2TM (Aerojet chemicals, Collinso Cordova, CA).
  • AMC-2TM Arojet chemicals, Collinso Cordova, CA
  • the reaction is carried out at 90-105 °C, with 2.0-5.0 wt % catalyst based on the total weight of the reaction mixture.
  • Known 1 may be reacted with methacrylic acid in refluxing acetonitrile catalyzed with 12-25 mol % TBAB, based on the number of moles of Known 1.
  • the resultant product is also Products 5 and 5a. This reaction can be monitored for completion using acid number titrations.
  • Products 5 and 5a have the formulae: and
  • Both of synthetic routes 4 and 5 open the epoxide rings on Known 1 to produce two free hydroxyl groups.
  • These hydroxyl groups can be further functionalized with a number of different R groups.
  • R groups include acrylates, methacrylates, maleates, glycidyl ethers, or an alkyl, alkenyl or aryl substituent.
  • Synthetic route 6 of Figure 1 is maleination of Known 0, which results in Product 6.
  • Known 0 and maleic anhydride are melted together to form a homogeneous solution before adding a base catalyst and stirring at 75-95 °C for 2-5 hours.
  • Product 6 can be used as a cross-linking agent, or it can be used as an intermediate for synthetic routes 7 and 8.
  • Product 6 has the formula:
  • Synthetic routes 7 and 8 in Figure 1 are analogous reactions wherein the treatment of Product 6 with a glycidyl vinyl ester, such as glycidyl acrylate or glycidyl methacrylate, produces Products 7 and 8, respectively.
  • a glycidyl vinyl ester such as glycidyl acrylate or glycidyl methacrylate
  • Use of the AMC-2TM catalyst in 0.5-3.0 wt% based on the total reaction mixture at low temperatures results in the formation of the desired product in excellent yields.
  • synthetic routes 7 and 8 can be carried out by TBAB catalyzed refluxing in acetonitrile.
  • This reaction can be monitored using acid number titrations until the desired acid number is reached and the reaction is complete.
  • Product 7 has the formula:
  • Product 8 has the formula:
  • Synthetic route 9 of Figure 1 is the dehydration of Known 0, where Known 0 is dissolved in solvent, preferably with a boiling point greater than 100 °C, with 5-35 mol %, based on the starting sugar, of acid catalyst and gently heated to between 50-80 °C to distill Product 9.
  • Product 9 has the formula:
  • the anhydrosugar-based monomers have been characterized both chemically and physically. Infrared (IR) spectra for each individual monomer show absorbance peaks in the expected regions for key functional groups. Nuclear Magnetic Resonance ( 1 H NMR) experiments have also been used for structure confirmation. Chemical shifts for 1 H NMR peaks are in agreement for each monomer and appear as expected. Physical properties of these monomers have also been tested and found to have melting points ranging from and exhibited viscosities in the starting at 120 cP to being unmeasurable without the aid or reactive diluent. Overall, these anhydrosugar-based monomers are low-cost, have a low viscosity and low volatility and possess multiple polymerizable sites. These monomers are also reactive with other vinyl ester monomers.
  • the anhydrosugar-based monomers are ideally suited for use as vinyl ester cross-linkers.
  • the anhydrosugar-based monomers exhibit suitable viscosities for producing new resins with low viscosity that require a minimal amount of reactive diluent.
  • These anhydrosugar-based monomers can partially or completely replace petroleum-based cross-linkers used in the manufacture of vinyl ester resins.
  • the anhydrosugar-based monomeric cross-linkers are used as the only vinyl ester cross-linkers in the vinyl ester resin systems.
  • the anhydrosugar-based monomers may be used as viscosity modulators.
  • the anhydrosugar-based monomers have a confined core structure resulting from the limited carbon chain length of the naturally occurring sugars from which they are derived.
  • the small core of these anhydrosugar monomers results in relatively low molecular weight anhydrosugar-based monomers that can be employed to reduce the overall viscosity of vinyl ester resins because of their low molecular weight in comparison with petroleum-based, relatively high molecule weight cross-linkers.
  • the monomers are well-suited for modulating the viscosity of vinyl ester resins by varying the amount of anhydrosugar-based monomer used in blends with petroleum-based, high viscosity cross-linkers.
  • the anhydrosugar-based monomers may be used as glass transition temperature (Tg) enhancers in vinyl ester resins to the desired level while also decreasing the viscosity.
  • Tg glass transition temperature
  • the anhydrosugar-based monomers of the present invention may be used to raise the Tg's of a resin system using bio-based reactive diluents without increasing the overall viscosity.
  • the Tg of of vinyl ester resins increases as the anhydrosugar-based monomer concentration increases.
  • the anhydrosugar-based monomers may be used as Tg enhancers for vinyl ester resin systems.
  • the ideal Tg for vinyl ester resins can be varied over a wide range of, for example, 40 - 250 °C, depending on the intended end use and the temperatures at which the resins will be used.
  • the amount of anhydrosugar-based monomer in a particular vinyl ester resin system may be varied in order to achieve the desired Tg for the vinyl ester resin.
  • Exemplary reactive diluents suitable for use in the present invention are petroleum-based and bio-based compounds with a single polymerizable site.
  • Suitable petroleum-based reactive diluents include, but are not limited to, styrene, 2-hydroxymethacrylate, methyl methacrylate, methyl acrylate, aryl-methacrylates, aryl-acylates, aliphatic methacrylates, aliphatic acrylates.
  • Suitable bio-based reactive diluents include, but are not limited to, furfuryl methacrylate, tetrahydrofurfuryl methacrylate, furfuryl acrylate, tetrahydrofurfuryl acrylate, furioc acid glycidyl methacrylate (FA-GM), furioc acid glycidyl acrylate and methacyrlated lauric acid, methacrylated octanoic acid, methacrylated fatty acids, and acrylated fatty acids.
  • a ternary resin system may also be formed by blending one or more anhydrosugar-based monomers with vinyl ester resins and reactive diluents.
  • Ternary compositions will typically include up to 60%, more preferably, 5-15% by weight of reactive diluent(s) and 40-99%, more preferably, 85-95% by weight of vinyl ester cross-linker monomers, wherein the composition of the cross-linker monomers is 15-99% by weight anhydrosugar-based monomers and 1-70% by weight of vinyl ester resin and/or unsaturated polyester monomer, more preferably, 15-70% by weight anhydrosugar-based monomers and 30-70% by weight of vinyl ester resin and/or unsaturated polyester monomer, with the all weights being based on the weight of the product resin mixture.
  • the unsaturated polyester monomer may be made from one or more of the following components: phthalic acid, terephthalic acid, m-phthalic acid, suberic acid, adipic acid, succinic acid, maleic acid, fumaric acid, butylene glycol, propylene glycol, and ethylene glycol, but is not limited to unsaturated polyesters made therefrom.
  • compositions comprise 5-95% by weight by weight of anhydrosugar-based monomers, 5-65% by weight of vinyl ester resin monomer and/or unsaturated polyester monomer and 0-50% by weight of at least one reactive diluent, or 15-90% by weight of anhydrosugar-based monomers, 10-55% by weight of vinyl ester resin monomer and/or unsaturated polyester monomer and 0-45% by weight of at least one reactive diluent.
  • the vinyl ester resin is preferably a petroleum-based vinyl ester.
  • the vinyl ester resins of the present invention are used as monomers and include, but are not limited to, commercial vinyl esters, which are vinyl esters that are commercially available, and which may be derived from any source. A broad range of commercial vinyl esters are suitable for use in the ternary resin systems of the present invention.
  • suitable vinyl esters are methacrylated, acrylated glycidyl ethers of bisphenols and novolac vinyl esters.
  • Suitable bisphenols include bisphenol A, hexafluorobisphenol A, bisphenol E, bisphenol F, tetramethyl bisphenol E, tetramethyl bisphenol F, bisphenol M, bisphenol C, bisphenol P and bisphenol Z. Methacrylates and acrylates of ethoxylated bisphenols may also be employed, as well as methacrylates of acrylates of epoxy products.
  • Vinyl esters with vinyl functionality greater than two may also be employed. Examples include acrylic and alkyl-acrylic vinyl esters of epoxy novolacs, and acrylates of tris-hydroxyphenylmethane glycidyl ether (THPM-GE), ethoxy phenol novolacs, and ethoxylated tris-hydroxyphenylmethane.
  • THPM-GE tris-hydroxyphenylmethane glycidyl ether
  • brominated versions of the above systems such as brominated bisphenol A based vinyl esters, may be employed.
  • the preferred vinyl esters for use in the ternary systems of the present invention are the bisphenol vinyl esters due to the desirability of making structural composites from the resultant polymers.
  • the anhydrosugar-based monomers of the present invention can be added to enhance the Tg of certain resins and/or to adjust the resin viscosity to improve the flow characteristics.
  • the addition of the anhydrosugar-based monomers also increases the sustainability of the resins, and reduces the reliance on reactive diluents, such as styrene, while maintaining or improving on the properties of petroleum-based resins.
  • Use of the anhydrosugar-based monomers in varying concentrations in relation to the petroleum-based vinyl ester and reactive diluents components can allow for the tailoring of the resin properties for specific applications and the tailoring of the properties of polymeric materials that result from these resins.
  • the resins containing the anhydrosugar-based monomers can be cured using any method that makes use of free-radically initiated reactive curing systems, including, but not limited to thermal cure, room temperature cure, electron beam cure, and ultraviolet cure.
  • the anhydrosugar-based monomers can be polymerized to form linear, branched, hyperbranched, and cross-linked polymers for a wide array of applications, including biosensors, rheology modifiers, biomaterials, and polymerizable surfactants for media encapsulation.
  • the anhydrosugar-based monomers can also be used for the production of polymer matrix composites, which are used in military, automotive, recreational, and marine applications. Exemplary products that may be made from these polymer matrix composites include body panels and armor for vehicles, composite hoods, and boat hull structures.
  • these polymer matrix composites can be used with traditional thermosetting vinyl and polyester resins as a gel coating material to provide a protective coating for composites and other surfaces.
  • anhydrosugar-based monomers as vinyl ester cross-linkers, Tg enhancers and viscosity modulators has been tested experimentally and found to be successful.
  • isosorbide as the starting point of the synthesis of the anhydrosugar-based monomers.
  • the isosorbide may be substituted with either isomannide or isoidide without any affect on the outcome of the reaction, yielding similar resin systems that result in comparable polymer systems.
  • Isosorbide was melted at 68°C before adding hydroquinone (0.2 mol %) and 2.0-2.5 molar equivalents of acrylic acid or methacrylic acid.
  • a catalytic amount of acid such as p -toluenesulfonic acid (0.5-2.5 wt %)
  • the reaction temperature was raised to 130-145°C and the progress followed by acid number titrations.
  • the reaction mixture was cooled to room temperature and dissolved in ethyl acetate.
  • the organic solution was washed sequentially with aqueous saturated sodium bicarbonate, water and aqueous sodium chloride and dried over MgSO 4 .
  • the solvent was removed under reduced pressure and the product appeared as a pale yellow to light brown oil. 1 H NMR analysis showed that the degree of (meth)acrylation was 1.7-2.0 (meth)acrylate groups per molecule.
  • Neat monomer with a chemical structure similar to a vinyl ester, i.e., Product 2 was free-radically polymerized by the addition of 0.375 wt% Cobalt Naphthanate (CoNap) and 1.5 wt% Trigonox 239 A (Trigonox).
  • the neat resin was purged with nitrogen prior to the addition of initiator and promoter for approximately 15 minutes to prevent oxygen inhibition during curing.
  • the purged resin mixture with added initiator and promoter were poured into a silicone mold and allowed to cure at room temperature inside an oven with a constant low flow of nitrogen to avert oxygen inhibition.
  • Neat monomer with chemical structure similar to polyester resin, i.e., Product 8 was free-radically polymerized with the addition of 0.375 wt% Cobalt Naphthanate (CoNap) and 1.5 wt% methyl ethyl ketone peroxide (MEKP).
  • the neat resin was purged with nitrogen prior to the addition of initiator and promoter for approximately 15 minutes to prevent oxygen inhibition during curing.
  • the purged resin mixture with added initiator and promoter were poured into a silicone mold and allowed to cure at room temperature inside an oven with a constant low flow of nitrogen to avert oxygen inhibition.
  • a partial bio-based monomer blend was formulated in a ratio of 35:65 wt% of styrene, as a reactive diluent, to Product 2, as a cross-linker, respectively.
  • the formulated monomer blend had a Newtonian viscosity of 5 cP at 25°C.
  • the cured monomer blend was free-radically polymerized at room temperature and post cured at 190°C for 2 hours.
  • DMA results showed a Tg of approximately 212°C and a storage modulus of 3,234 MPa at 25°C.
  • a partial bio-based three-component monomer blend was formulated in a ratio of 10:80:10 wt% of Product 2, methacrylated epoxy RDX 26936 (RDX), as a vinyl ester resin mixture, and styrene, as a reactive diluent, respectively.
  • the formulated monomer blend had a Newtonian viscosity of 8,981 cP at 25°C.
  • the cured monomer blend was free-radically polymerized at room temperature and post cured at 190°C for 2 hours.
  • DMA results showed a Tg of approximately 145°C and a storage modulus of 2,893 MPa at 25°C.
  • a partial bio-based three-component monomer blend was formulated in a ratio of 50:40:10 wt% of Product 2, RDX, as a vinyl ester resin mixture, and styrene, as a reactive diluent, respectively.
  • the formulated three-component monomer blend had a Newtonian viscosity of 480 cP at 25°C.
  • the cured monomer blend was free-radically polymerized at room temperature and post cured at 200°C for 2 hours.
  • DMA results showed a Tg of approximately 169°C and a storage modulus of 2,893 MPa at 25°C.
  • a partial bio-based three-component monomer blend was formulated in a ratio of 80:10:10 wt% of Product 2, RDX, as a vinyl ester resin mixture, and styrene, as a reactive diluent, respectively.
  • the formulated three-component monomer blend had a Newtonian viscosity of 68 cP at 25°C.
  • the cured monomer blend was free-radically polymerized at room temperature and post cured at 190°C for 2 hours.
  • DMA results showed a Tg of approximately 244°C and a storage modulus of 3,352 MPa at 25°C.
  • a bio-based monomer blend was formulated in a ratio of 35:65 wt% of furfuryl methacrylate, as a reactive diluent, to Product 2, as a cross-linker, respectively.
  • the formulated monomer blend had a Newtonian viscosity of 16 cP at 25°C.
  • the cured monomer blend was free-radically polymerized at room temperature and post cured at 145°C for 2 hours.
  • DMA results showed a Tg of approximately 122°C and a storage modulus of 3,421 MPa at 25°C.
  • a bio-based three-component monomer blend was formulated in a ratio of 10:80:10 wt% of Product 2, RDX, as a vinyl ester resin mixture, and furfuryl methacrylate, as a reactive diluent, respectively.
  • the formulated three-component monomer blend had a Newtonian viscosity of 22,830 cP at 25°C.
  • the cured monomer blend was free-radically polymerized at room temperature and post cured at 170°C for 2 hours.
  • DMA results showed a Tg of approximately 128°C and a storage modulus of 3,404 MPa at 25°C.
  • a bio-based vinyl ester ternary monomer system was formulated in a ratio of 50:40:10 wt% of Product 2, RDX, as a vinyl ester resin mixture, and furfuryl methacrylate respectively.
  • the formulated monomer blend had a Newtonian viscosity of 701 cP at 25°C.
  • the cured, bio-based three-component monomer blend was free-radically polymerized at room temperature and post cured at 195°C for 2 hours.
  • DMA results showed a Tg of approximately 157°C and a storage modulus of 3,525 MPa at 25°C.
  • a bio-based vinyl ester three-component monomer blend was formulated in a ratio of 80:10:10 wt% of Product 2, RDX, as a vinyl ester resin mixture, and furfuryl methacrylate respectively.
  • the formulated three-component monomer blend had a Newtonian viscosity of 92 cP at 25°C.
  • the cured, bio-based three-component monomer blend was free-radically polymerized at room temperature and post cured at 190°C for 2 hours.
  • DMA results showed a Tg of approximately 263°C and a storage modulus of 3,455 MPa at 25°C.
  • a bio-based two-component monomer blend was formulated in a ratio of 35:65 wt% of methacrylated lauric acid (MLau) to Product 2 respectively.
  • the formulated monomer blend had a Newtonian viscosity of 73 cP.
  • the cured, bio-based two-component monomer blend was free-radically polymerized at room temperature and post cured at 110°C for 2 hours.
  • DMA results showed a Tg of approximately 107°C and a storage modulus of 2,220 MPa at 25°C.
  • a bio-based vinyl ester three-component monomer blend was formulated in a ratio of 10:80:10 wt% of Product 2, RDX, as a vinyl ester resin mixture, and MLau respectively.
  • the formulated three-component monomer blend had a Newtonian viscosity of 58,995 cP at 25°C.
  • the cured, bio-based three-component monomer blend was free-radically polymerized at room temperature and post cured at 160°C for 2 hours.
  • DMA results showed a Tg of approximately 169°C and a storage modulus of 3,322 MPa at 25°C.
  • a bio-based vinyl ester three-component monomer blend was formulated in a ratio of 50:40:10 wt% of Product 2, RDX, as a vinyl ester resin mixture, and MLau respectively.
  • the formulated three-component monomer blend had a Newtonian viscosity of 1,445 cP at 25°C.
  • the cured, bio-based three-component monomer blend was free-radically polymerized at room temperature and post cured at 180°C for 2 hours.
  • DMA results showed a Tg of approximately 165°C and a storage modulus of 3,206 MPa at 25°C.
  • a bio-based vinyl ester three-component monomer blend was formulated in a ratio of 80:10:10 wt% of Product 2, RDX, as a vinyl ester resin mixture, and MLau respectively.
  • the formulated three-component monomer blend had a Newtonian viscosity of 153 cP at 25°C.
  • the cured, bio-based three-component monomer blend was free-radically polymerized at room temperature and post cured at 125°C for 2 hours.
  • DMA results showed a Tg of 193°C and a storage modulus of 2,927 MPa at 25°C.
  • a partial bio-based monomer blend was formulated in a ratio of 80:20 wt% Product 2, as a viscosity modulator, to ViapalTM 450 Unsaturated Polyester Resin (UPE), as a cross-linker, respectively.
  • the formulated monomer blend had a Newtonian viscosity of 1,098 cP at 25°C.
  • the cured monomer blend was free-radically polymerized at room temperature and post cured at 110°C for 2 hours.
  • DMA results showed a Tg of approximately 58°C and a storage modulus of 3,623 MPa at 25°C.
  • a partial bio-based three-component monomer blend was formulated in a ratio of 50:40:10 wt% of Product 2, UPE, as a resin mixture, and furfuryl methacrylate (FM), as a reactive diluent, respectively.
  • the formulated three-component monomer blend had a Newtonian viscosity of 700 cP at 25°C.
  • the cured monomer blend was free-radically polymerized at room temperature and post cured at 110°C for 2 hours.
  • DMA results showed a Tg of approximately140 °C and a storage modulus of 157 MPa at 25°C.
  • a partial bio-based monomer blend was formulated in a ratio of 50:50 wt% of Product 2, as a viscosity modulator, to RDX, as a cross-linker, respectively. Following curing by the procedure described in example 5, the cured monomer blend was free-radically polymerized at room temperature and post cured at 110 °C for 2 hours. DMA results showed a Tg of approximately 130 °C and a storage modulus of 3200 MPa at 25 °C.
  • a partial bio-based monomer blend was formulated in a ratio of 80:20 wt% of Product 2, as a viscosity modulator, to RDX, as a cross-linker, respectively. Following curing by the procedure described in example 5, the cured monomer blend was free-radically polymerized at room temperature and post cured at 110 °C for 2 hours. DMA results showed a Tg of approximately 212 °C and a storage modulus of 3100 MPa at 25 °C.

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Claims (14)

  1. Verfahren zum Herstellen eines Polymers, umfassend den Schritt des Härtens einer Zusammensetzung, umfassend
    mindestens ein Monomer auf Zuckeranhydrid-Basis, ausgewählt aus Monomeren mit Strukturen von:
    Figure imgb0024
    Figure imgb0025
    Figure imgb0026
     und
    Figure imgb0027
    Figure imgb0028
    und mindestens ein Vinylesterharz-Monomer oder ungesättigtes Polyestermonomer und gegebenenfalls ein reaktives Verdünnungsmittel,
    wobei die Zusammensetzung 1 bis 99 % Massenanteil Monomere auf Zuckeranhydrid-Basis, 1 bis 70 % Massenanteil Vinylesterharz-Monomer oder ungesättigtes Polyestermonomer und 0 bis 60 % Massenanteil mindestens eines reaktiven Verdünnungsmittels beinhaltet, wobei sich alle Massenanteilsprozente auf die Masse der Zusammensetzung beziehen.
  2. Verfahren nach Anspruch 1, wobei die Zusammensetzung 5 bis 95 % Massenanteil Monomere auf Zuckeranhydrid-Basis, 5 bis 65 % Massenanteil Vinylesterharz-Monomer oder ungesättigtes Polyestermonomer und 0 bis 50 % Massenanteil mindestens eines reaktiven Verdünnungsmittels umfasst.
  3. Verfahren nach Anspruch 1, wobei die Zusammensetzung 15 bis 90 % Massenanteil Monomere auf Zuckeranhydrid-Basis, 10 bis 55 % Massenanteil Vinylesterharz-Monomer oder ungesättigtes Polyestermonomer und 0 bis 45 % Massenanteil mindestens eines reaktiven Verdünnungsmittels umfasst.
  4. Verfahren nach Anspruch 1, wobei die Zusammensetzung 40 bis 99 % Massenanteil einer Vernetzermonomer-Zusammensetzung und 0 bis 60 % Massenanteil eines reaktiven Verdünnungsmittels, bezogen auf eine Gesamtmasse der härtbaren Zusammensetzung, umfasst, wobei die Vernetzermonomer-Zusammensetzung 15 bis 99 % Massenanteil des Monomers auf Zuckeranhydrid-Basis und 1 bis 70 % Massenanteil des Vinylesterharzes oder des ungesättigten Polyestermonomers beträgt.
  5. Verfahren nach Anspruch 1, wobei die Zusammensetzung 40 bis 99 % Massenanteil einer Vernetzermonomer-Zusammensetzung und 0 bis 60 % Massenanteil eines reaktiven Verdünnungsmittels, bezogen auf eine Gesamtmasse der härtbaren Zusammensetzung, umfasst, wobei die Vernetzermonomer-Zusammensetzung 15 bis 70 % Massenanteil des Monomers auf Zuckeranhydrid-Basis und 30 bis 70 % Massenanteil des Vinylesterharzes oder des ungesättigten Polyestermonomers beträgt.
  6. Verfahren nach einem der Ansprüche 1 bis 5, wobei das reaktive Verdünnungsmittel ausgewählt ist aus der Gruppe bestehend aus Styrol, 2-Hydroxymethacrylat, Methylmethacrylat, Methylacrylat, Furfurylmethacrylat, methacrylierter Laurinsäure und methacrylierten Fettsäuren.
  7. Verfahren nach Anspruch 6, umfassend das Vinylester-Monomer, wobei das Vinylester-Monomer ausgewählt ist aus der Gruppe bestehend aus (meth)acrylierten Glycidylethern von Bisphenolen, (meth)acrylierten ethoxylierten Bisphenolen und Novolak-Vinylestern.
  8. Verfahren nach Anspruch 7, wobei die Bisphenole ausgewählt sind aus der Gruppe bestehend aus Bisphenol A, Hexafluorbisphenol A, Bisphenol E, Bisphenol F, Tetramethylbisphenol E, Tetramethylbisphenol F, Bisphenol M, Bisphenol C, Bisphenol P und Bisphenol Z.
  9. Verfahren nach Anspruch 6, umfassend das ungesättigte Polyestermonomer, wobei das ungesättigte Polyestermonomer aus einer oder mehreren der folgenden Bestandteile hergestellt ist: Phthalsäure, Terephthalsäure, m-Phthalsäure, Octandisäure, Adipinsäure, Bernsteinsäure, Maleinsäure, Fumarsäure, Butylenglykol, Propylenglykol und Ethylenglykol.
  10. Verfahren nach einem der Ansprüche 1 bis 9, wobei das Härten ein durch freie Radikale eingeleitetes reaktives Härtungssystem verwendet, vorzugsweise eine thermische Härtung, eine Raumtemperaturhärtung, eine Elektronenstrahlhärtung oder eine Ultravioletthärtung.
  11. Verfahren nach einem der Ansprüche 1 bis 10, wobei das Monomer ausgewählt ist aus einem Monomer der Formel 1 und einem Monomer der Formel 1a.
  12. Verfahren nach einem der Ansprüche 1 bis 10, wobei das Monomer ausgewählt ist aus einem Monomer der Formel 2 und einem Monomer der Formel 2a.
  13. Ein Copolymer, erhältlich durch das Verfahren nach einem der Ansprüche 1 bis 12.
  14. Verwendung von mindestens einem Monomer auf Zuckeranhydrid-Basis, ausgewählt aus Monomeren mit Strukturen von:
    Figure imgb0029
    Figure imgb0030
    Figure imgb0031
     und
    Figure imgb0032
     um die Glasübergangstemperatur eines Vinylesterharz-Polymers zu erhöhen.
EP12845143.2A 2011-08-10 2012-08-10 Verfahren zur herstellung von polymeren mit erhöhter glasübergangstemperatur aus biobasierten erneuerbaren (meth)acrylierten monomeren in anwesenheit von vinylestermonomeren oder ungesättigten polyestermonomeren Active EP2742055B1 (de)

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